Case studies of ergonomic interventions in automotive parts distribution operations.

Ergonomic job analysis, intervention design, and intervention implementation are essential components of an ergonomics program designed to reduce worker exposure to risk factors associated with musculoskeletal disorders. As part of a 4-year study to reduce overexertion injuries in the service parts division of a major automaker, intervention case studies were identified that could be used at multiple facilities across the division. Interventions were developed and implemented. The three case studies include 1) self-elevating powered vehicle for transporting parts throughout the facility and for reaching to high bin locations; 2) lift and tilt pallet jacks for packing small parts into large bin-like containers; and 3) single-level telescoping conveyor used for delivering hand-held totes for subsequent sorting operations. Several analysis methods were used to assess worker exposure before and after intervention implementation (biomechanical analysis, posture analysis, worker interviews, and activity analysis). Following implementation, a decrease in exposure to risk factors for musculoskeletal disorders was documented. Worker interviews revealed acceptance and agreement that risk factors associated with the targeted tasks were reduced. Each case study includes a description of the implementation hurdles and can serve as both primary and secondary prevention of musculoskeletal disorders. Future work should document worker health and/or symptom changes as well as changes in risk factor exposure.